Reciprocators_en

Reciprocators and axes
Cost reduction and quality improvement
through automation
Automatic powder coating systems
Making the right choice of automation will save time and
money!
Gema offers a broad range of multi-axis systems with
different levels of automation selected to meet the
individual needs of the customer.
Your global partner for high quality powder coating

The base for all motion
Reliable and precise
Quiet running, individual programming options and stability
combined with high loading capacity are indispensable for uniform
powder coating. The reciprocators of the ZA series meet these
requirements perfectly and feature a solid and maintenance-friendly
design. They constitute the base for all automation, from simple
vertical strokes to complex and multidimensional processes.
Benefits of the ZA reciprocators
– Long-stroke and short-stroke operation
– Tooth belt transmission for quiet running
– Maintenance-free AC-motor
– Narrow column design for space-saving gun configurations
OptiMove Control
The OptiMove axis control unit is user-friendly, allowing ease of
programming. Each control module controls a single axis. Despite its
compact design, OptiMove offers many functions normally found in
more complex control units.
Features:
– Programming via touch panel
– Up to 255 programs
– Segment operation and stroke adjustment
– Cycle times displayed
– Integrated DigiBus / CAN-bus

Detection of gaps,
height and width
Gap detection
The gap control turns off the guns where a gap is detected. For this
application a light barrier detects the object to be coated at the booth
entrance and the guns are activated just before the object passes
through. In case of a gap, the guns are turned off after the object has
passed.
Height detection
For the height detection a light grid is used, which automatically
triggers the required guns. With horizontal gun arrangement, the
reciprocator stroke lengths are automatically adapted to the object
heights.
Width detection
In addition to the gap and height detection systems, the width detection
automatically adjusts the reciprocators via X-axis to variable object
widths. Ideally the guns are arranged vertically, so that the object
contour can be scanned exactly.
Standard axes for all applications
Z-axis:
This is the standard axis. It moves the guns in
a vertical direction.
X-axis:
This axis moves the reciprocator horizontally
for the width adjustment. The X-axis is also
used for the automatic gun cleaning via
blow-off nozzles.
X-axis
Z-axis

Multidimensional
solutions
Synchronization with conveyor (Y-axis)
This option is used for the inner coating of hollow bodies such as ovens
and control cabinets. A shaft encoder synchronizes the reciprocators
to the chain speed, guaranteeing accurate coating of edges, recessed
parts and internal features. The ideal coating data is calculated
beforehand and stored in a database, where it can be recalled at any
time.
Infeed axes (U-axis)
For special object geometries and applications, there are different
axes available (with rotating axes if required). These are equipped with
an independent drive, which accurately moves the gun in and out of
predefined zones.
Special axes for complex applications
Z-axis
U-axis:
The U-axis moves the single guns horizontally,
one by one, into the recessed areas of the object.
R-axis
R-axis:
Rotates the spray gun around its own axis.
Y-axis:
Moves the reciprocator synchronized with the
conveyor along the booth.
U-axis
Y-axis
X-axis

Robots and rotating axes
Rotating axes (R-axis)
Rotating axes are ideally suited for the coating of inner edges and
recessed parts (for example on control cabinets and rotating parts).
They accurately trace the rounded geometries and guarantee optimum
coating results even on difficult-to-reach areas.
Robots
When the highest flexibility and free programming are required,
robots offer the perfect solution. The programming is done via
“teach-in”. The geometry and motion sequences are tracked with the
spray gun, whereas the robot stores the data for the coating process.
Special axes – Solutions for
complex applications
Special application cases need
special solutions. Thanks to our
vast experience and wide range
of products, we will find, in close
collaboration with you, the ideal
axis geometry for your specific
needs.

MagicControl ® CM30
All parameters under control
MagicControl CM30 module controls all parameters of the powder
coating plant. The individual application layout is shown on the screen,
and all operations and functions are transmitted in real-time.
Individual programming
You program all parameters directly on the screen. With clear
symbols, the touch screen displays the action messages. Different
security levels prevent programs and parameters being modified by
mistake.
Storing with maximum security
To maintain security, coating programs and parameters can be stored
onto memory cards.
What is CAN-Bus?
A bus system allows the
data exchange between the
hardware components and
the control module CM30/
CM22, controlling the powder
coating system.
The bidirectional Data
exchange between the
hardware components
ensures a comfortable and
process-safe Data exchange.
PLC control units for fully automated coating
MagicControl is a fully
programmable, central control
module for controlling the booth,
the gun control units, the
reciprocators, the axes and the
powder supply. MagicControl
allows for interlocking and data
exchange with higher-level plant
control units.
The control and command of height, width and depth detection are
easily executed via monitor with touch-screen function and large display.
Clear symbols offer a simple and intuitive operation. The coating
programs and production data are stored on CompactFlash cards and
can be recalled at any time.

Cost reduction and quality
improvement with Gema
reciprocators and axes
Benefits of the ZA reciprocators
– Long-stroke and short-stroke operation
– Tooth belt transmission for quiet running
– Maintenance-free AC-motor
– Narrow column design for space-saving
gun configurations
– Broad assortment of axes
– Wide range of control options
– Positioning accuracy within a millimeter
– Vast program diversity
The powder coating world of
Gema

Gema Switzerland
Your global partner for high quality
powder coating
Take advantage of our expertise and experience from
more than 40 years of electrostatic powder coating
applications. From simple hand coating through to fully
automated powder coating, we offer solutions that meet
the demands and requirements of customers around
the world in a wide range of industrial sectors. A global
service network ensures you always get professional
support, at any time and any place!
Gema is part of Graco Inc. Our goal is to help our
customers to increase their productivity while creating
attractive, long-lasting products. Our experts
continually set new standards in the surface coating
industry.
009675-EN-06-2016
Gema Switzerland GmbH reserves the right to make technical modifications without
notice. Illustrations in brochures may contain special options and do not necessarily
correspond to the standard version. OptiCenter, MagicCenter, OptiSpeeder,
MagicCompact, MagicCylinder, OptiFlex, OptiStar, OptiGun, OptiSelect, MagicControl,
OptiControl and OptiFlow are trademarks of Gema Switzerland GmbH.
Gema Switzerland GmbH
Mövenstrasse 17 | 9015 St.Gallen | Switzerland
T +41 71 313 83 00 | F +41 71 313 83 83
www.gemapowdercoating.com